API RP-576 Inspection of Pressure-relieving Devices

PRESSURE RELIEVING DEVICES

Cairo Inspection Company Eng. Ibrahim Eldesoky

ASNT –NDT-- LEVEL III ASME AUTHORIZED INSPECTOR API AUTHORIZED INSPECTOR

Definitions

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3.1.1 car seal: A self-locking seal that when placed in position and closed, locks and must be cut with wire cutters or physically broken to be removed. Local jurisdictional requirements may specify the acceptable method (s) of sealing or locking block valves. 3.1.2 non-reclosing pressure relief device: A pressure relief device, which remains open after operation. A manual resetting means may be provided.

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3 Definitions •

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3.1.3 pin-actuated device: A non-reclosing pressure relief device actuated by static pressure and designed to function by buckling or breaking a pin which holds a piston or a plug in place. Upon buckling or breaking of the pin, the piston or plug instantly moves to the full open position. 3.2.1 effective discharge area: A nominal or computed area used with an effective discharge coefficient to calculate the minimum required relieving capacity for a pressure relief valve per the preliminary sizing equations contained in API RP 520. API Std 526 provides effective discharge areas for a range of sizes in terms of letter designations, “D’ through “T”. 3.2.2 huddling chamber: An annular pressure chamber located downstream of the seat of a pressure relief valve for the purpose of assisting the valve to achieve lift. Cairo Inspection Company (CIC)

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API 510 / API 576

Descriptions of Pressure Relieving Devices

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Safety Valves

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Principle of Operation A safety valve is a direct spring-loaded pressure relief valve that is actuated by the static pressure upstream of the valve and characterized by rapid opening or pop action. Description The spring of a safety valve is usually fully exposed, out-side of the valve bonnet to protect it from degradation due to the temperature of the relieving medium.

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Safety Valves • •

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Applications A safety valve is normally used with compressible fluids. Safety valves are used on steam boiler drums and superheaters. They may also be used for general air and steam services in refinery and petrochemical plants. Limitations Safety valves should not be used as follows: a. In corrosive services (unless isolated from the process by a rupture disk). b. Where the discharge must be piped to remote locations or a closed system. c. Where the escape of process fluid around blowing valves is not desirable. d. In liquid service. e. As pressure control or bypass valves. Cairo Inspection Company (CIC)

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Relief Valves Description • A relief valve is a direct spring-loaded pressure relief valve actuated by the static pressure upstream of the valve. The valve opens normally in proportion to the pressure increase over the opening pressure. • Principle of Operation • A relief valve begins to open when the static inlet pressure reaches set pressure. • When the static inlet pressure overcomes the spring force, the disk begins to lift off the seat. • Relief valves usually reach full lift at either 10% or 25% overpressure, depending on the type of valve and trim. • These valves have closed bonnets to prevent the release of corrosive, toxic, flammable, or expensive fluids. •

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Relief Valves

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Figure 2 illustrates one type of relief valve. The ASME Code requires that liquid service relief valves installed after January 1, 1986 have their capacity certified and stamped on the nameplate

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Relief Valves

Applications • Relief valves are normally used for incompressible fluids. • Limitations • Relief valves should not be used as follows: • a. In steam, air, gas, or other vapor services. • b. In services piped to a closed header unless the effects of any constant or variable back pressure has been accounted for. • c. As pressure control or bypass valves. •

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Safety Relief Valve

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Description A safety relief valve is a direct spring-loaded pressure relief valve that may be used as either a safety or relief valve depending on the application. A safety relief valve is normally fully open at 10% overpressure when in gas or vapor service. When installed in liquid service, full lift will be achieved at approximately 10% or 25% overpressure, depending on trim type.

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Safety Relief Valve with O-ring Seal Some relief valves are manufactured with resilient O-rings or other types of soft seats to supplement or replace the conventional metal-to-metal valve seating surfaces. Figure 3 illustrates one type of Oring seat seal as installed in a safety relief valve.

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Conventional Safety Relief Valve

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Description A conventional safety relief valve is a direct spring loaded pressure relief valve whose operational characteristics (opening pressure, closing pressure, and relieving capacity) are directly affected by changes in the back pressure (see Figure 4).

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Conventional Safety Relief Valve • •

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Description A conventional safety relief valve has a bonnet that encloses the spring and forms a pressure-tight cavity. The bonnet cavity is vented to the discharge side of the valve. Applications Conventional safety relief valves can be used in refinery and petrochemical processes that handle flammable, hot, or toxic material. The effect of temperature and back pressure on the set pressure must be considered when using conventional safety relief valves.

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Conventional Safety Relief Valve • • • •

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Limitations Conventional safety relief valves should not be used in the following applications: a. Where any built-up back pressures exceeds the allowable overpressure. b. Where the Cold Differential Test Pressure CDTP cannot be reduced to account for the effects of variable back pressure (see API RP 520 Part I). c. On ASME Section I steam boiler drums or ASME Section I superheaters. d. As pressure control or bypass valves.

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Balanced Safety Relief Valve • •

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Description A balanced safety relief valve is a direct spring loaded pressure relief valve that incorporates a bellows or other means for minimizing the effect of back pressure on the operational characteristics of the valve. Whether it is pressure tight on its downstream side depends on its design. See figures 5 and 6. Limitations Balanced safety relief valves should not be used as follows: a. On ASME Section I steam boiler drums or ASME Section I superheaters.

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Balanced Safety Relief Valve

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b. As pressure control or bypass valves. Balanced type valves require vented bonnets. A bellows failure allows process media from the discharge side of the valve to discharge from the bonnet vent. Consider the nature of the process media (e.g., liquid/vapor, toxicity, and flammability) when evaluating the bonnet vent disposition.

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Pilot-Operated Pressure Relief Valve

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Description A pilot-operated safety relief valve is a pressure relief valve in which the major relieving device or main valve is combined with and controlled by a self actuated auxiliary pressure relief valve (pilot). Depending on the design, the pilot valve (control unit) and the main valve may be mounted on either the same connection or separately. The pilot is a spring loaded valve that operates when its inlet static pressure exceeds its set pressure. This causes the main valve to open and close according to the pressure.

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Pilot-Operated Pressure Relief Valve • •

Description Process pressure is either vented off by the pilot valve to open the main valve or applied to the top of the unbalanced piston, diaphragm, or bellows of the main valve to close it.

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Pilot-Operated Pressure Relief Valve •

Applications

Pilot-operated safety relief valves are generally used as follows: a. Where a large relief area and/or high set pressures are required, since pilot-operated valves can usually be set to the full rating of the inlet flange. b. Where a low differential exists between the normal vessel operating pressure and the set pressure of the valves. c. On large low-pressure storage tanks (see API Std 620). d. Where very short blow down is required •

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Pilot-Operated Pressure Relief Valve• Limitations • Pilot-operated safety relief valves are not generally used as follows: a. In service where fluid is dirty, unless special provisions are taken (such as filters, sense line purging, etc.) b. In viscous liquid service, as pilot-operated valve operating times will increase markedly due to flow of viscous liquids through relatively small passages within the pilot. c. With vapors that will polymerize in the valves. d. In-service where the temperature exceeds the safe limits for the diaphragms, seals, or O-rings selected. e. Where chemical compatibility of the lading fluid with the diaphragms, seals, or O-rings of the valves is questionable. f. Where corrosion buildup can impede the actuation of the pilot. •

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Rupture Disk Devices •

The combination of a rupture disk holder and rupture disk is known as a rupture disk device. A rupture disk device is a non-reclosing pressure relief device actuated by the static differential pressure between the inlet and outlet of the device and designed to function by the bursting of a rupture disk. A rupture disk device includes a rupture disk and a rupture disk holder (see Figure 12).

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Rupture Disk Devices a. A rupture disk is a pressure containing, pressure and temperature sensitive element of a rupture disk device. Rupture disks may be designed in several configurations, such as flat, domed (prebulged), or reverse acting. The rupture disk holder secures the disk in place. b. nonfragmenting rupture disk is a rupture disk designed and manufactured to be installed upstream of other piping components, such as pressure relief valves, and will not impair the function of those components when the disk ruptures. c. A rupture disk holder is the structure, which encloses and clamps the rupture disk in position. Rupture disks normally require a rupture disk holder although some disks are designed to be installed between standard flanges without holders. Cairo Inspection Company (CIC)

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Conventional Rupture Disk

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A conventional domed rupture disk is a pre bulged solid metal disk designed to burst when it is over pressured on the concave side (see Figure 13).

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Conventional Rupture Disk

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The conventional domed rupture disk of flat-seat or angularseat design generally provides a satisfactory service life when operating conditions are 70% or less of the rated burst pressure of the disk and when limited pressure cycling and temperature variations are present. If vacuum or back pressure conditions are present, the disk must be furnished with a vacuum support to prevent reverse flexing or implosion. Vacuum supports are designed for continuous service at full vacuum or less. Special designs are available for back pressure conditions that exceed 15 lbf/in.2 (103 kPa). The conventional domed rupture disk will fragment upon burst.

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Scored Tension-Loaded Rupture Disk

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The scored tension-loaded rupture disk is designed to open along scored lines (see Figure 14).

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Scored Tension-Loaded Rupture Disk •

This type of disk is designed to allow a closer ratio (generally 85%) of system operating pressure to disk burst pressure. Because the score lines control the opening pattern, this type of disk is normally nonfragmenting. The scored tension-loaded rupture disk is manufactured from thicker material than is used for unscored disks for the same burst pressure.

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Composite Rupture Disk •

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A composite rupture disk is a flat or domed metallic or nonmetallic multi-piece construction disk. The domed composite rupture disk is designed to burst when it is over pressured on the concave side. The domed composite rupture disk, available in flat-seat or angular-seat design, permits typical operation to 80% of the rated burst pressure under limited pressure cycling and temperature variations.

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Composite Rupture Disk

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A flat composite rupture disk is available for the protection of low-pressure vessels or the isolation of equipment such as exhaust headers or the outlet sides of pressure relief valves. Intended as corrosion barriers only, flat composite rupture disks may typically operate at 50% of the rated burst pressure and are generally installed between companion flanges rather than specific rupture disk holders. Rupture disks that act in either direction are available; these provide positive pressure and vacuum protection.

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Reverse-Acting Rupture Disk •

A reverse-acting rupture disk is a domed solid metal disk designed to burst when it is overpressured on the convex side. Reverse-acting rupture disks are designed to open by such methods as shear, knife blades, knife rings, or scored lines (see Figures 15 and 16).

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Reverse-Acting Rupture Disk •

The reverse-acting rupture disk is designed to allow a closer ratio of system operating pressure to burst pressure, up to 90% of the rated burst pressure. This type of disk is usually nonfragmenting. Because the reverse-acting rupture disk is actuated by overpressure on the convex side, thicker disk materials may be used, thereby improving corrosion resistance, eliminating the need for vacuum support, and providing longer service life under pressure/vacuum cycling conditions and temperature fluctuations. Caution should be exercised when inspecting reverse acting disk utilizing knife blade. If the knife edges become dull, the knife may not sever the disk. High overpressures may result.

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Graphite Rupture Disk •

A graphite rupture disk is manufactured from graphite impregnated with a binder material and designed to burst by bending or shearing (see Figure 17).

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Graphite Rupture Disk

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Graphite rupture disks are resistant to most acids, alkalis, and organic solvents. Operation to 70% of the rated burst pressure is generally permissible. A support may be required for disks that are rated 15 lbf/in.2 (103 kPa) or less; a support also may be required under conditions of higher back pressure. Graphite rupture disks fragment upon rupture; provisions for capturing fragments may be required in certain applications.

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Applications Rupture disk devices are sometimes used as follows: a. To protect the upstream side of pressure relief valves against corrosion by the system fluid. b. To protect pressure relief valves against plugging or clogging by viscous fluids or polymerization products. c. Instead of pressure relief valves if the protected system can tolerate process interruptions or loss of fluids in case the disk ruptures. d. Instead of pressure relief valves if extremely fast response is desirable. •

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Applications

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e. As secondary pressure-relieving devices when the difference between the operating pressure and the rupture pressure is large, depending on the type of rupture disk selected. f. To protect the downstream sides of pressure relief valves against downstream corrosion from headers or against atmospheric corrosion. g. To minimize process/product leakage and reduce fugitive emissions.

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Limitations •

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For pre-bulged metal rupture disks installed so that pressure acts against the concave side and for flat metal rupture disks, the operating pressure of the protected system is usually limited to 65-85% of the disk's predetermined bursting pressure. The exact percentage depends on the type of disk used. The service life of prebulged metal rupture disks under normal operating conditions is usually one year. They are subject to relatively rapid creep stress failure, especially at high operating temperatures. * If not replaced periodically, they may fail without warning at normal operating pressures. Cairo Inspection Company (CIC)

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Limitations •

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Higher operating pressures (up to 90% of the disk design bursting pressure) are possible with the reverse-buckling disk. Less fatigue due to pulsating and cyclic operating pressure results in a longer service life than would be expected if the disk were installed with the pressure acting against the con-cave side. Most reverse-buckling disks should not be used in liquid full service. However, if an assured gas pocket rests against the disk and the disk manufacturer is consulted, liquid service can be considered. With finite lives, these disks should be replaced periodically. Consult the manufacturer for recommended replacement times.

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Limitations •

Impervious graphite rupture disks offer nearly the same advantages and disadvantages as the reverse-buckling, metal type. However, with impervious graphite rupture disks, the piping arrangement may be more complicated and uneven flange bolt loads or thermal strains in the piping may crack the disk.

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Rupture disks that tend to fragment, such as conventional and graphite disks, are typically not installed beneath pressure relief valves unless a means of protecting the pressure relief valve inlet from the fragments is provided.

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API 510 / API 576

Causes of Improper Performance of Pressure Relieving Devices

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Corrosion •

Nearly all types of corrosion are present in refinery and chemical plant services. Corrosion is a basic cause of many of the difficulties encountered with pressure relief devices. Corrosion often appears as: pitted or broken valve parts, deposits of corrosive residue that interfere with the operation of the moving parts, or a general deterioration of the material of the relieving device. Figures 19 through 25 illustrate the effects of corrosion on relief devices. In addition to internal parts, exposed studs are vulnerable to environmental corrosion attack.

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Corrosion

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Damaged Seating Surfaces

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Because differential loading must be small to prevent leak-age of the lading fluid, an optical precision on the order of 3 light beads/bands [0.0000348 in. (0.0008838 mm)] must be maintained in the flatness of seating surfaces on metal-seated pressure relief valves (see API Std 527). Any imperfection in these seating surfaces will contribute to improper valve action in service.

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Damaged Seating Surfaces There are many causes of damaged valve seats in refinery or chemical plant service, including the following: a. Corrosion. b. Foreign particles that get into the valve inlet and pass through the valve when it opens., c. Improper or lengthy piping to the valve inlet or obstructions in the line. These can cause a valve to chatter. d. Careless handling during maintenance, such as bumping, dropping, jarring, or scratching of the valve parts. e. Leakage past the seating surfaces of a valve after it has been installed. This leakage contributes to seat damage by causing erosion (wire drawing) or corrosion of the seating surface. •

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Failed Springs •

Spring failure occurs in two forms. The first is a weakening of the spring, which causes a reduction in set pressure and the possibility of premature opening. The second is a total failure (complete break) of the spring, which causes uncontrolled valve opening.

Improper Setting and Adjustment •

Manuals provided by the valve manufacturer help eliminate improper setting and adjustment by indicating how to adjust their valves for temperature, back pressure, and other factors.

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Plugging and Sticking •

Valve malfunction may also be due to sticking of the disk or disk holder in the guide which may be caused by corrosion or galling of the metal or by foreign particles in the guiding surfaces. Foreign particles in the guiding surfaces tend to roll metal up, causing severe galling. The use of a bellows can keep the foreign particles away from the guiding surfaces.

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Sticking of valves can also result from machining of valve parts outside the manufacturer's tolerance limits. Figure 35 shows a disk that is frozen in the guide as a result of corrosion in sour gas service. If corrosion is the cause of the sticking, three possible cures are available.

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Misapplication of Materials •

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Manufacturers can usually supply valve designs and materials that suit special services. Catalogs show a wide choice of special materials and accessory options for various chemical and temperature conditions. Addition of a rupture disk device at the inlet or outlet may help prevent corrosion. The hydrogen sulfide (H 2 S) attack on the carbon steel spring in Figure 22 and the chloride attack on the 18Cr-8Ni steel disk in Figure 23 exemplify the results of the misapplication of materials. Where service experience indicates that a selected valve type or material is not suitable for a given service condition, an immediate correction that will ensure dependable operation should be made. Cairo Inspection Company (CIC)

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Misapplication of Materials

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Improper Location, History, or Identification •

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If not installed at the exact location for which it was Intended a pressure relief valve might not provide the proper protection. To assist in the identification of valves and to provide information necessary for correct repairs and installation, a comprehensive set of specification and historical records should be maintained and referred to when valves are removed for inspection and repair. Most pressure relief valves have an identifying serial or shop number placed on the valve by the manufacturer or an identifying number tagged, stamped, or otherwise placed on the valve by the user. Some users also stamp mating pipe flanges with device numbers. This identification specifies the location of the valve and, by reference to the specification record, its limitations and construction (see Section 7). Cairo Inspection Company (CIC)

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Rough Handling •

Valves are checked for tightness in the manufacturer's plant before they are shipped to the user. Valve tightness is sometimes checked by the user in the maintenance shop before initial use and usually checked after subsequent cleaning, repairing, or testing. Subsequent rough handling of the valve, however, can change the set pressure, damage lifting levers, damage tubing and tubing fittings, damage pilot assemblies or cause internal or external leakage when the valve is in service.

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Rough Handling Rough handling can occur during shipment, maintenance, or installation. During Shipment • Because of their operation, most pressure relief valves have a sturdy appearance that may obscure the fact that they are delicate instruments with very close tolerances and sensitive dimensions. Accordingly, commercial carriers sometimes subject them to rough handling. This may cause a valve to leak excessively in service or during testing. •

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Rough Handling •

During Maintenance

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Careful handling of the valve during all phases of maintenance is important. Both before and after repairs, rough handling of the completely assembled valve should be avoided. Before the valves leave the shop, valve inlets and outlets should be covered. Rough handling during maintenance includes application of excessive back pressure, which should not be applied to a bellows valve during a maintenance-related test.

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Rough Handling •

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During Installation Valve inlets and outlets should have been covered before the valves left the shop. If they were not covered when received for installation, provisions should be made to ensure that in the future they are covered before leaving the shop. Pressure relief valves should be transported in an upright position. Rough handling of a pressure relief valve by personnel during installation may cause poor valve performance in service.

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Improper Differential Between Operating and Set Pressures

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The differential between operating and set pressures provides seat loading to keep the pressure relief valve tightly closed. Due to a variety of service conditions and valve designs, only general guidelines can be given for designing a system.

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Improper Discharge Piping Test Procedures When hydrostatic tests of discharge piping are performed, blinds must be installed. Otherwise, results such as the following might occur: a. The disk, spring, and body area on the discharge side of the valve are fouled. b. The bellows of a balanced relief valve are damaged by excessive back pressure. c. The dome area and/or pilot assembly of a pilot-operated pressure relief valve are fouled and damaged by the backflow of fluid.

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API 510 / API 576

Inspection and Testing

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Shop Inspection/Overhaul

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Periodically, pressure relief devices will be removed, disassembled, and inspected. These inspections are referred to as "shop inspection/overhaul" (although some, if not all of the work can be performed in the field).

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Also, while the device is removed, inlet and outlet piping should be inspected for the presence of internal deposits, and records should be kept of their condition. If heavy fouling is observed, the piping should be cleaned. If necessary, piping should be dismantled for inspection and cleaning.

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Valve Identification •

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To minimize errors in the testing and handling of pressure relief valves, each should carry an identifying tag, stencil, plate, or other means to show its company equipment number. This number allows ready identification of the device's unit, the equipment that the device should be installed on, the device's set pressure, and the date of its last test (see Figure 37 for an example of an identifying tag).

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Operating Conditions Noted

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An operating history of each pressure relief valve since its last inspection should be obtained and should include pertinent information such as:

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a. Information on upsets and their effect on the valve. b. The extent of any leakage while in service. c. Any other evidence of malfunctioning.

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Initial Inspection

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Many types of deposits or corrosion products in a pressure relief valve may be loose and may drop out during transportation of the valve to the shop for inspection, testing, maintenance, and resetting. As soon as a valve has been removed from the system, a visual inspection should be made. Figure 39 shows sulfur deposits in a valve. When fouling is a frequent problem, it may be prudent to collect samples for testing and to record deposit locations and appearances. Any obstructions in the valve should be recorded and removed. Cairo Inspection Company (CIC)

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Inspection of Adjacent Inlet and Outlet Piping •

Inspection of the piping at the pressure relief valve will often indicate the condition of the process piping whose interior is not visible. Piping should be checked for corrosion, indications of thinning, and deposits that could interfere with valve operation. The character of the deposits may indicate the cause of any leakage from the valve in a closed system.

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59

Transportation of Valves to Shop

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After a pressure relief valve is removed from its installation, it should be transported to the shop for inspection, testing, maintenance, and resetting. Before moving the valve, flange faces on the valve (and flanges on the piping) should be protected so that gasket faces are not damaged. The valves should be transported in the upright position.

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Transportation of Valves to Shop • Determining •

"As Received” Pressure

Pop

Check that the seals are intact on the pressure set screw cover and blow down ring screw cover. Before the valve is dismantled, the pop pressure of the valve when removed from service should be obtained. Generally the pressure relief valve is mounted on the test block, and the inlet pressure is slowly increased. The pressure at which the valve relieves is recorded as the "as received" pop pressure. Typically, the inlet pressure is not increased beyond 150% of the pressure relief valve set pressure.

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Visual Inspection During inspection the points that should be checked include: a. The flanges, for evidence of pitting, roughening, or decreases in the width of seating surfaces. b. The springs, for evidence of corrosion or cracking and for the correct pressure range at the valve's operating pressure and temperature. c. If the valve is of the bellows type, the bellows for evidence of corrosion, cracking or deformation. d. The positions of the set screws and openings in the bonnet. e. The inlet and outlet nozzles, for evidence of deposits of foreign material or corrosion. • i. The pilots and associated parts •

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Visual Inspection

f. The external surfaces, for any indication of a corrosive atmosphere or of mechanical damage. g. The body wall thickness. h. Valve components and materials, for a match with the information on the identification tag and specification card.

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Setting of Valve Set Pressure •

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Normally, the deviation of the pop pressure from the set pressure should not exceed ±2 lbf/in.2 (±13.8 kPa) for pressures less than or equal to 70 lbf/in.2 (483.0 kPa) or ±3% for pressures greater than 70 lbf/in.2 (483.0 kPa) Follow the valve manufacturer’s recommended testing procedure when the pressure relief valve is tested with water. Typically, the pressure will be raised slowly to the required setting. The discharge should be observed for evidence of leakage, or the test gauge should be observed for a momentary drop in pressure. A small continuous stream of water from the valve discharge usually indicates attainment of the CDTP.

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Checking Valve for Tightness

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Once the valve is set to pop at its CDTP, it should be checked for leakage. On the test block, it can be tested for seat tightness by increasing the pressure on the valve to 90% of the CDTP and observing the discharge side of the valve for evidence of leakage. Methods of determining leakage are covered in Appendix B.2 and Figure 40.

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Where applicable, the bonnet, bellows, gasketed joints and auxiliary piping/tubing should be inspected for leakage.

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Eng. Ibrahim Eldesoky

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Checking Valve for Tightness •

Figure 40 API 576

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Eng. Ibrahim Eldesoky

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Completion of Necessary Records •

All necessary records should be completed before a valve is placed back into service. By helping to determine when to replace the components of the valve and when to retire it, the records are critical to its effective future use. They form the historical record of the conditions and services under which the valve operated. Retention of maintenance and test records may be required by governmental regulations.

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See Appendix A for example forms. For an explanation of nameplate terms required by repair work, see API Std 526.

Cairo Inspection Company (CIC)

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Eng. Ibrahim Eldesoky

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